FAST EVALUATION OF CUTTING FORCES IN MILLING, APPLYING NO APPROXIMATEMODELS

A new method for fast evaluation of cutting forces in milling is intro duced and tested experimentally. Unlike all existing procedures, which include the use of cutting models and approximate assumptions, in thi s method, the elementary functions of the cutting force are obtained f rom measured values only. The basic force functions for the whole feed range are acquired from one experiment using a single-tooth full-diam eter (slot) milling, applying a specially developed procedure. The mil ling experiment is conducted under low-impact conditions, enabling acc urate measurement and convenient signal processing. The basic force fu nctions are then integrated and superimposed using known procedures, t o combine the total force in any multitooth milling combination. In th is work the method is explained and tested experimentally. The suggest ed method enables a reliable evaluation of the cutting forces, while d emanding minimal experimental work, the method applies to cutters havi ng complicated edge geometry, and to high speed milling.